Experimental Analysis of Material Squeeze Factor in Two-Point Incremental Forming of AL 7075-O

2020 ◽  
Author(s):  
Ankush Bansal ◽  
Randy Cheng ◽  
Mihaela Banu ◽  
Alan Taub ◽  
Jun Ni
Keyword(s):  
Incremental Forming ◽  
Sheet Thickness ◽  
Processing Parameters ◽  
Wall Region ◽  
Forming Process ◽  
Die Surface ◽  
Complex Shapes ◽  
Al 7075 ◽  
Geometric Deviation ◽  
Metal Products

Abstract In recent years, incremental sheet forming (ISF) has shown significant potential for economically fabricating sheet metal products required in low volume. Despite its advantages of reduced forming forces and higher material formability, manufacturing complex shapes with acceptable geometric accuracy is still a challenging task. Two-point ISF (TPIF) is one variant that uses a support die to a fabricate part with intricate features. In this study, effects of material squeeze factor in the TPIF process is investigated on part accuracy and formability. Material squeeze factor is defined as the amount of sheet thickness squeezed between the forming tool and support die. It is integrated as one of the processing parameters for generating a pre-defined toolpath of the forming process. However, the effective material squeeze (SFe) obtained in experiments is either zero or significantly lower than the squeeze factor programmed (SFp) in the toolpath due to machine and tool compliance. SFp values are heuristically chosen in literature studies to maintain steady contact between the sheet and die surfaces and avoid forming through degenerated SPIF rather than the “true” TPIF process. For a 67° cone, the part kept losing contact with the die surface below SFp = 30% whereas uniform contact between sheet and die surface is achieved for SFp = 40%. Also, the geometric deviation is significantly reduced from 0.61 mm to 0.39 mm along the wall region with the higher squeeze factor. Similar results are obtained for a benchmark heart shape part.

scholarly journals Study on Thickness Thinning Ratio of the Forming Parts in Single Point Incremental Forming Process

2018 ◽  
Vol 2018 ◽  
pp. 1-11 ◽  
Author(s):  
Mingshun Yang ◽  
Zimeng Yao ◽  
Yan Li ◽  
Pengyang Li ◽  
Fengkui Cui ◽  
...  
Keyword(s):  
Deformation Zone ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Feeding Speed ◽  
Forming Angle ◽  
Tool Diameter ◽  
Thinning Rate

An excessive thickness-reducing ratio of the deformation zone in single point incremental forming of the metal sheet process has an important influence on the forming limit. Prediction of the deformation zone thickness is an important approach to control the thinning ratio. Taking the 1060 aluminum as the research object, the principle of thickness deformation in the single point incremental forming process was analyzed; the finite element model was established using ABAQUS. A formula with high accuracy to predict the deformation zone thickness was fitted with the simulation results, and the influences of process parameters, such as tool diameter, step down, feeding speed, sheet thickness, and forming angle, on thinning ratio were analyzed. The accuracy of the finite element simulation was verified by experiment. A method to control the thinning rate by changing the forming trajectory was proposed. The results showed that the obtained value by using the fitted formula is closer to the experimental results than that obtained by the sine theorem. The thinning rate of the deformation zone increases with the increase of tool diameter, forming angle, and sheet thickness and decreases with the increase of step down, while the feeding speed had no significant effect on the thinning ratio. The most important factor of the thinning ratio is the forming angle, and the thinning ratio can be effectively reduced by using the forming trajectory with a uniformly distributed pressing point.

Experimental Tests to Study Feasibility and Formability in Incremental Forming Process

2009 ◽  
Vol 410-411 ◽  
pp. 391-400 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Antonio Fiorentino ◽  
Luca Mazzoni ◽  
Claudio Giardini
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Experimental Tests ◽  
Final Part ◽  
Cnc Machine ◽  
Forming Process ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF), a sheet metal forming process, that knew a wide development in the last years. It consists of a simple hemispherical tool that, moving along a defined path by means of either a CNC machine or a robot or a self designed device, locally deforms a metal sheet. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility as a function of the process parameters; to define models able to forecast the final sheet thickness as a function of the drawing angle and tool path strategy; to understand how the sheet deforms and how formability limits can be defined. Nowadays, a lot of these topics are still open. In this paper, the results obtained from an experimental campaign performed to study sheet formability and final part feasibility are reported. The ISF tests were conducted deforming FeP04 deep drawing steel sheet 0.8 mm thick and analyzing the influence of the tool path strategy and of the adopted ISF technique (Single Point Incremental Forming Vs. Two Points Incremental Forming). The part feasibility and formability were evaluated considering final sheet thickness, geometrical errors of the final part, maximum wall angle and depth at which the sheet breaks. Moreover, process forces measurements were carried out by means of a specific device developed by the Authors, allowing to obtain important information about the load acting on the deforming device and necessary for deforming sheet.

Driving – A Flexible Manufacturing Method for Individualized Sheet Metal Products

2010 ◽  
Vol 447-448 ◽  
pp. 795-800
Author(s):  
Daniel Scherer ◽  
Z. Yang ◽  
H. Hoffmann
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Flexible Manufacturing ◽  
Incremental Forming ◽  
Industrial Robot ◽  
General Information ◽  
Work Piece ◽  
Forming Process ◽  
Manufacturing Method ◽  
Metal Products

This paper provides general information about the qualification of driving as an on-demand manufacturing concept for the production of individualized sheet metal products. Driving allows the creation of almost any 2D or 3D geometry, but it is a highly interactive, manual production process. Due to the inevitable variations of the incremental forming process (mechanical properties, tribology, wear etc.) and the high number of forming steps, it cannot be automated by traditional approaches. At the Institute of Metal Forming and Casting (Technische Universitaet Muenchen) a kraftformer machine has been equipped with measuring and controlling instrumentation. An optical online measurement system is installed to detect any geometry deformation of the current work piece and to visualize the deviation between the actual and the stored reference geometry during the whole production process. This variance comparison is the first step for planning any following incremental forming actions based on acquired and/or learned knowledge. The second step is the integration of an industrial robot for work piece handling and the automation of the whole manufacturing process. The last step is the integration of neural networks to predict production strategies for any desired unique geometry.

Experimental Investigation on the Formability of 7075 Al – Alloy Sheet in Superplastic Forming Technique

2012 ◽  
Vol 622-623 ◽  
pp. 442-446 ◽  
Author(s):  
G. Kumaresan ◽  
K. Kalaichelvan
Keyword(s):  
Sheet Thickness ◽  
Superplastic Forming ◽  
Alloy Sheet ◽  
Al Alloy ◽  
Strain Rates ◽  
Superplastic Behavior ◽  
Variable Parameters ◽  
Complex Shapes ◽  
Al 7075 ◽  
Temperature Ranges

Superplastic behavior of certain metals and alloys having very fine grains, very large tensile elongations are obtained within certain temperature ranges at low strain rates. These alloys can be formed into complex shapes by superplastic forming, a process that employs common metalworking techniques. This paper aims to study the formability characteristic for aluminium material (Al 7075) by considering variable parameters such as sheet thickness of 1.75 and 1.5 mm and the temperature of 520°C and 530°C.

scholarly journals Parameter optimization for deformation energy and forming quality in single point incremental forming process using response surface methodology

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771011 ◽  
Author(s):  
Zimeng Yao ◽  
Yan Li ◽  
Mingshun Yang ◽  
Qilong Yuan ◽  
Pengtao Shi
Keyword(s):  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Deformation Energy ◽  
Geometric Error ◽  
Forming Process ◽  
Wall Angle ◽  
Forming Quality ◽  
Step Down

The deformation energy in single point incremental forming has an immediate impact on the processing cost, the heat and the wear effects between the tool and the formed material. Meanwhile, poor forming quality is still one of the largest challenges for the development and commercialization of this method. Therefore, the goal of this study is to search for the optimal working condition for lower energy consumption with better forming quality during the forming process. A Box–Behnken design for a cone parts forming process has been performed. The effects of four input parameters (step down, tool diameter, wall angle, and initial sheet thickness) on three outputs—deformation energy, surface roughness, and geometric error—have been investigated. With the target of minimal synchronization of deformation energy consumption, surface roughness, and geometric error, which are 1522.4 J, 0.97 µm, and 1.939 mm, respectively, in this case, four processing parameters were optimized with tool diameters as 16 mm, step down as 0.5 mm, sheet thickness as 0.57 mm, and wall angle as 65°. With optimization of deformation energy and surface roughness, in conjunction with geometric error compensation, an increased accuracy of the resulting parts can be obtained with minimum deformation energy and surface roughness.

Manufacturing of Sheet Metal Components with Variants Using Process Adapted Semi-Finished Products

2012 ◽  
Vol 504-506 ◽  
pp. 1023-1028 ◽  
Author(s):  
Marion Merklein ◽  
Raoul Plettke ◽  
Thomas Schneider ◽  
Simon Opel ◽  
Daniel Vipavc
Keyword(s):  
Sheet Metal ◽  
Sheet Thickness ◽  
Forming Process ◽  
Local Loads ◽  
Bulk Forming ◽  
Orbital Forming ◽  
Metal Products ◽  
2D And 3D ◽  
Process Combination ◽  
Specific Control

Manufacturing of functional sheet metal products by forming can be realised with the application of conventional bulk forming operations on sheet metals. The challenges of those sheet bulk metal forming processes are high resulting forming forces and the demand on a specific control of material flow. To meet these challenges well-directed thinning of blanks as well as accumulations of material to form functional elements is employed. Due to local loads, simultaneous 2D and 3D stress and strain states occur. Process adapted semi-finished products, containing a defined sheet thickness characteristic, are formed in the presented work by the technologies upsetting and orbital forming. Orbital forming is an incremental bulk forming operation to decrease the forming zone extension and consequently the required process force. Afterwards a process combination of deep drawing and upsetting in order to manufacture a cup-shaped workpiece with external gearing is presented. The results of this integrated single-stage forming process are discussed and subsequently the potential to enhance the process limits is shown by using process adapted semi-finished products.

Formability Analyses on Single Point Incremental Sheet Forming Process on Aluminum 1050

2019 ◽  
Vol 969 ◽  
pp. 703-708
Author(s):  
Dawit Desalegn ◽  
P. Janaki Ramulu ◽  
Dagmawi Hailu ◽  
S. Senthil Kumaran ◽  
P. Velmurugan ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Forming Process ◽  
Aluminum 1050 ◽  
Tool Diameter ◽  
Truncated Pyramid

In recent years, there is a lot of demand on metal forming processes in which sheet metal forming process has lots of applications in the automotive and aerospace industries. In sheet metal forming operations, incremental forming is an emerging technology in which, single point incremental forming (SPIF) process is die-less in incremental forming process and providing a competitive alternative to economical and effective in fabricating low volume products. The objective of this work is to analyze the forming analysis on truncated pyramid product by avoiding cracking and maintaining the optimum forming conditions. The formability is analyzed by using ABAQUS software and simulation, different process parameters were varied such as sheet thickness, tool diameter, step depth, spindle rotational speed on aluminum AA1050 alloy. From the simulation results, stress stain and stain distribution were evaluated on the deformed sheet. The product produced is truncated pyramid dimension having square base of side and fillet at corner.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

Stress Analysis of Sheet Metal Vibration Incremental Forming

2010 ◽  
Vol 154-155 ◽  
pp. 166-170
Author(s):  
Gai Pin Cai ◽  
Ning Yuan Zhu ◽  
Na Wen
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Low Frequency ◽  
Forming Process ◽  
Technical Parameters ◽  
Vibration Technique ◽  
Low Frequency Vibration ◽  
Metal Deformation ◽  
Angle Effect ◽  
Forming Angle

As a non-homogenous force stresses during incremental forming, sheet metal easily tended to instability, and some defects, such as deposition, wrinkle and fracture, would appear. If the vibration technique was combined the incremental forming process, its deformation mechanism would be different from that of the old process, and sheet metal deformation quality was also risen. Then some mechanical equations were built by force analyzed on element in local contact zone of die head forcing down. According to reasonable hypothesis and simplified, the equations were solved. Some stress-time curves of the element were obtained by given process parameters, vibrational parameters and time parameters. It is shown from analysis that stress variety of the element is closely related to amplitude, frequency and forming angle, effect of sheet metal vibration incremental forming with high frequency vibration is more superior than that of with low frequency vibration; only when vibrational parameters are reasonably matching technical parameters, the effective vibration incremental forming can be obtained.

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